Apparatuses and Methods For Seaming Substrates

ABSTRACT

A method of joining substrate portions includes positioning the substrate portions such that the substrate portions overlap at an overlap area. The substrate portions each have a melting temperature and an outer surface. A fluid is heated to a temperature sufficient to at least partially melt the substrate portions. A jet of the heated fluid is directed from a fluid orifice onto the substrate portions at the overlap area. The heated fluid penetrates at least one of the outer surfaces of the substrate portions. The substrate portions are at least partially melted using the heated fluid. The substrate portions are compressed using a pressure applying surface adjacent the fluid orifice to join the substrate portions together at the overlap area.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of application Ser. No. 13/401,907filed on Feb. 22, 2012, which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to methods for manufacturing absorbentarticles, and more particularly, to apparatuses and methods for seamingtwo or more partially meltable materials.

BACKGROUND

Disposable absorbent articles, in particular, disposable diapers, aredesigned to be worn by people experiencing incontinence, includinginfants and invalids. Such diapers are worn about the lower torso of thewearer and are intended to absorb and contain urine and other bodilydischarges, thus preventing the soiling, wetting, or similarcontamination of articles that may come into contact with a diaperduring use (e.g., clothing, bedding, other people, etc.). Disposablediapers are available in the form of pull-on diapers, also referred toas training pants, having fixed sides. The fixed sides may bemanufactured by joining side panels of the front portion of the diaperto side panels of the rear portion of the diaper. For joining purposes,the contacting surfaces of the side panels may be at least partiallymelted by directing heated fluid to areas of the contacting surfaces.Pressure may then be applied to the partially melted areas.

Consequently, during the process of joining substrates together, itwould be beneficial to provide methods and apparatuses for moreprecisely directing the heated fluid and applying pressure to thepartially melted areas of the substrates.

SUMMARY

Aspects of the present disclosure involve apparatuses and methods formanufacturing absorbent articles, and more particularly, methods forseaming substrates during the manufacture of disposable absorbentarticles. Particular embodiments of methods of manufacture disclosedherein provide for forming side seams in various types of diaperconfigurations. While the present disclosure relates mainly to formingside seams in diaper pants, it is to be appreciated that the methods andapparatuses disclosed herein can also be applied to other seams used ondiapers as well as other types of absorbent articles.

In one embodiment, a method for forming a seam includes the steps of:providing an anvil block; providing a forming block adjacent the anvilblock, the forming block comprising a face, a pressure applying memberextending outwardly from the face toward the anvil block, and a fluidorifice in the face spaced laterally from the pressure applying member;advancing a first substrate in a machine direction between the formingblock and the anvil block with a separation distance between the fluidorifice and the first substrate; advancing a second substrate in themachine direction wherein the first substrate is between the secondsubstrate and the forming block; controlling the separation distancebetween the first substrate and the fluid orifice; heating a fluid to atemperature sufficient to at least partially melt the substrates;directing a jet of the heated fluid through the fluid orifice and ontoan overlap area of the first and second substrates; partially meltingthe overlap area; and compressing the overlap area between the pressureapplying member and the anvil block.

In another embodiment, the method for forming a seam includes the stepsof: providing an anvil block; providing a forming block adjacent theanvil block, the forming block comprising a face, a pressure applyingmember extending outwardly from the face toward the anvil block, and afluid outlet extending through a portion of the forming block and spacedlaterally from the pressure applying member; advancing a first substratein a machine direction between the forming block and the anvil blockwith a separation distance between the fluid orifice and the firstsubstrate; advancing a second substrate in the machine direction whereinthe first substrate is between the second substrate and the formingblock; controlling the separation distance between the first substrateand the fluid orifice; heating a fluid to a temperature sufficient to atleast partially melt the substrates; directing a jet of the heated fluidthrough the fluid orifice and onto an overlap area of the first andsecond substrates; partially melting the overlap area; and compressingthe overlap area between the pressure applying member and the anvilblock.

In another embodiment, a method for forming a seam includes the stepsof: providing an anvil block; providing a forming block adjacent theanvil block, the forming block comprising a face, a pressure applyingmember extending outwardly from the face toward the anvil block, and afluid outlet combined with the pressure applying member; advancing afirst substrate in a machine direction between the forming block and theanvil block with a separation distance between the fluid orifice and thefirst substrate; advancing a second substrate in the machine directionwherein the first substrate is between the second substrate and theforming block; controlling the separation distance between the firstsubstrate and the fluid orifice; heating a fluid to a temperaturesufficient to at least partially melt the substrates; directing a jet ofthe heated fluid through the fluid orifice and onto an overlap area ofthe first and second substrates; partially melting the overlap area; andcompressing the overlap area between the pressure applying member andthe anvil block.

These and additional features provided by the embodiments describedherein will be more fully understood in view of the following detaileddescription, in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments set forth in the drawings are illustrative and exemplaryin nature and not intended to limit the subject matter defined by theclaims. The following detailed description of the illustrativeembodiments can be understood when read in conjunction with thefollowing drawings, where like structure is indicated with likereference numerals and in which:

FIG. 1A illustrates an embodiment of substrate portions joined at aseam.

FIG. 1B illustrates another embodiment of substrate portions joined at aseam.

FIG. 1C illustrates another embodiment of substrate portions joined at aseam.

FIG. 2 is a simplified, schematic drawing of an embodiment of a rotaryseaming apparatus useful for joining two or more substrate portions.

FIG. 3 is a detailed view of the rotary apparatus of FIG. 2.

FIG. 4 is another detail view of the rotary apparatus of FIG. 2.

FIG. 4A is a perspective view of an embodiment of a pressure applyingmember and fluid outlet.

FIG. 4B is a perspective view of another embodiment of a pressureapplying member and fluid outlet.

FIG. 5 is a simplified, schematic drawing of another embodiment of aseaming apparatus useful for joining two or more substrate portions.

FIG. 6A illustrates the seaming apparatus of FIG. 5 in use.

FIG. 6B illustrates the seaming apparatus of FIG. 5 in use.

FIG. 7 is a simplified, schematic drawing of another embodiment of aseaming apparatus useful for joining two or more substrate portions.

FIG. 8 is a simplified, schematic drawing of another embodiment of aseaming apparatus useful for joining two or more substrate portions.

FIG. 9 is a simplified, schematic drawing of another embodiment of aseaming apparatus useful for joining two or more substrate portions.

FIG. 10 is a simplified, schematic drawing of another embodiment of aseaming apparatus useful for joining two or more substrate portions.

FIG. 11 is a simplified, schematic drawing of another embodiment of aseaming apparatus useful for joining two or more substrate portions.

FIG. 11A illustrates the seaming apparatus of FIG. 11 in use.

FIG. 11B illustrates the seaming apparatus of FIG. 11 in use.

FIG. 11C illustrates the seaming apparatus of FIG. 11 in use.

FIG. 12 is a perspective view of a diaper pant.

FIG. 13 is a partially cut away plan view of the diaper pant shown inFIG. 1.

FIG. 14 is a partially cut away plan view of a second embodiment of adiaper pant.

FIG. 15A is a cross-sectional view of the diaper pants of FIGS. 13 and14 taken along line 15A-15A.

FIG. 15B is a cross-sectional view of the diaper pants of FIGS. 13 and14 taken along lines 15B-15B.

DETAILED DESCRIPTION

The methods and apparatuses described herein relate to seamingsubstrates. In general, portions of substrates may be overlapped and ajet of heated fluid is delivered from an orifice to at least partiallymelt the overlapping substrate portions. More particularly, the jet ofheated fluid penetrates the substrate portions and at least partiallymelts the overlapping substrate portions where the substrate portionsinterface at an overlap area. The location of the substrate portionsrelative to the orifice may be controlled such that the substrateportions are held a predetermined distance away from the orifice duringthe heating operation. Pressure may then be applied at the overlap areathereby joining the substrate portions together. In all the embodimentsdescribed herein, the fluid may include ambient air or other gases.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

As used herein, the term “joining” describes a configuration whereby afirst element is directly secured to another element by affixing thefirst element directly to the other element.

As used herein, the term “substrate” is used herein to describe amaterial which is primarily two-dimensional (i.e. in an XY plane) andwhose thickness (in a Z direction) is relatively small (i.e. 1/10 orless) in comparison to its length (in an X direction) and width (in a Ydirection). Non-limiting examples of substrates include a substrate,layer or layers or fibrous materials, nonwovens, films and foils such aspolymeric films or metallic foils. These materials may be used alone ormay comprise two or more layers laminated together. As such, a web is asubstrate.

As used herein, the term “pull-on diaper” refers to a garment that isgenerally worn by infants and sufferers of incontinence, which is pulledon like pants. It should be understood, however, that the presentdisclosure is also applicable to other absorbent articles, such as tapeddiapers, incontinence briefs, feminine hygiene garments, and the like,including absorbent articles intended for use by infants, children, andadults.

As used herein, the term “inboard” refers to a first element or materialwhich is nearer the lateral or longitudinal centerline of an articlerelative to a second element or material, the second element or materialbeing “outboard” of the first.

As used herein, the term “porous” refers to a material having an airpermeability of at least 30 cm³/cm²/sec when tested according to thestandard test method for Permeability to Air; Cloth; Calibrated OrificeMethod, as described in Method 5450 of Federal Test Method Standard No.191A.

As used herein, the term “at least partially melted” refers to materialsat least a portion of which have reached at least a softening pointtemperature, but have not reached a melt point temperature. “Melted”also refers, in its ordinary sense, to materials which have exceededtheir melt point temperatures over at least a portion of the material.

In some aspects, the present disclosure relates to seams, methods formaking seams, articles comprising a seam, and methods for makingarticles comprising a seam. As described in greater detail below, a seammay be formed between two substrates, each substrate comprising one ormore meltable components. A seam may also be formed between portions ofthe same substrate that is, for example, folded along a fold line formedbetween the two substrate portions. The substrate portions to be seamedmay be positioned adjacent one another, and heated to at least asoftening temperature, or a melting temperature, to at least partiallymelt one or both of the substrate portions. The substrate portions maybe compressed after heating. The description which follows describesgenerally seams, methods for making seams and apparatus for makingseams. While various embodiments are separately described andillustrated, it is to be appreciated that various aspects of thedifferent embodiments can be combined to produce yet furtherembodiments, which may not be described explicitly for the purpose ofbrevity.

Schematic, fragmentary side elevational views of two substrate portionsto be joined are shown in FIGS. 1A, 1B and 1C. At least two substrateportions 11, 12 are arranged in an adjacent manner to form a seam 10.The seam 10 comprises outer surfaces 13, 14 and an area of overlap 15between the substrates 11, 12. FIG. 1A shows a configuration hereinreferred to as an overlap seam, wherein two or more materials are joinedalong adjacent, overlapping surfaces. FIG. 1B shows a configurationherein referred to as a butt seam, wherein two or more materials arejoined at or near their edges and the materials are folded back, awayfrom the seam. FIG. 1C illustrates substrate portions 11 and 12 that arepart of the same continuous substrate that are folded at a fold line Fand overlapped.

The joining of at least two substrate portions 11 and 12 that arearranged in an adjacent manner to form a seam 10, such as illustrated inFIG. 1A or 1B, may comprise providing a first substrate and folding thesubstrate to provide the substrate portions 11 and 12, where thesubstrate portions have a melting temperature and an outer surface 13,14, the melting temperatures of the first 11 and second substrates 12being substantially the same or substantially different. The seamingoperation may be accomplished in an integrated folding-and-sealing unit,as described, for example, in U.S. Pat. No. 5,779,831 to Schmitz. Insome embodiments, the substrate portions 11 and 12 may be part ofdifferent, separate substrates that are overlapped. The seamingoperation may further comprise a step of placing the substrate portion11 adjacent the substrate portion 12 to form the overlap area 15. Afluid may be sufficiently heated to enable at least a partial melting ofthe substrate portions 11, 12. A jet of the heated fluid may be directedtoward at least one of the outer surface 13 of the substrate portion 11and the outer surface 14 of the substrate portion 12. The fluid may beallowed to penetrate the substrate portions 11 and 12 such that at leasta portion of each of the substrate portions 11 and 12 is melted in theoverlap area 15. The heated fluid, at a controlled temperature andpressure, may pass from the fluid outlet, leading to the formation ofcontrolled and concentrated jets of heated fluid, which are directedtoward outer surfaces 13, 14 of substrate portions 11, 12 to be joined.

By controlled, it is meant that the temperature and pressure aremaintained within a specified range once the nominal set points areselected. For example, a set point may be selected from the rangesdiscussed above, and the temperature may then be maintained in a fixedrange around the nominal set point, such as ±30° C., and the pressuremay be maintained in a fixed range around the nominal set point, such as±1 bar. The acceptable range will depend on the relationship between theproperties, such as softening point and/or melting temperature, of thematerials to be joined and the nominal set point selected. For example,a nominal set point above the melting temperature of one or more of thematerials to be joined may require a tighter control range than anominal set point well below the melting temperature of one or morematerial to be joined. The control range may be asymmetrical about thenominal set point. By sufficiently heating, it is meant that the fluidis heated to a temperature that will enable at least partial melting, orat least softening, of the substrate or substrates. Sufficient heatingmay vary with the materials and equipment used. For example, if theheated fluid is applied to the substrate or substrates almostimmediately, with little or no time to cool, the fluid may be heated toapproximately the softening point or approximately the melting point ofthe substrate or substrates. If the heated fluid is directed to thesubstrate or substrates over some gap in time or distance, such that theheated fluid may cool somewhat before interacting with the substrate orsubstrates, it may be necessary to heat the fluid above, possiblysignificantly above, the softening point or melting point of thesubstrate or substrates.

The fluid may also be delivered to outer surfaces 13, 14 with a pulsedapplication. The impact of the jet of heated fluid may be adjusted suchthat both the energy introduced by the jet plus the energy introduced byother means such as the heated anvil (if the anvil is heated), jetnozzle surface, deformation of substrate portions 11, 12, and theinternal friction of substrate portions 11, 12 are sufficient to atleast partially melt the meltable components in substrate portions 11,12 to create a certain tackiness, which will form a strong joint at areaof overlap 15 upon compression. The melting of the meltable componentsmay occur in a non-uniform manner throughout substrate portions 11, 12.

The duration of energy transfer in the process described herein may be adynamic process, and may create a temperature gradient across the crosssections of the meltable components. That is, the core of the meltablecomponents may remain solid while the exterior surface of the meltablecomponents melt or come close to melting. Even below the meltingtemperature, the exterior surface may reach a softening point, such thatplastic deformation of the material may occur at a much lower load thanfor the same material at ambient temperature. Thus, if one or more ofthe materials to be joined in seam 10 have a softening point, theprocess may be adjusted to achieve a temperature in at least a portionof substrate portions 11, 12 between the softening point and the meltingpoint. The use of a temperature at or above the softening point butbelow the melting point of one or more of the meltable components mayallow for the creation of a strong bond between substrate portions 11,12 with reduced disruption to the structure of the meltable componentse.g., attenuating or otherwise weakening the meltable components.

As discussed in more detail below, methods of joining at least twosubstrate portions may further comprise the step of compressing seam 10with the one or more pressure applying member while the meltablecomponents are at least partially melted, and/or in the tacky state. Thetemperature of the pressure applying members may be at least below themelting point of seam 10. In some embodiments, the pressure applyingmember may be heated. The tackiness property of the meltable componentspermits the joining of substrate portions 11, 12 and thus, theaccumulation of melted substrate material may be reduced or avoided.Such melted material may form hard, raspy protuberances on the outersurfaces of seam 10 upon solidification. The pressure applying membersmay be designed according to aesthetic criteria, for example, to providediscrete, shaped points where substrate portions 11, 12 are joined.Discrete compression points may also make the seam easier to open, ifdesired. The compression points may generally take the shape and spacingof the pressure applying surfaces. As one example, the pressure applyingmembers may be generally oval, or may have any other geometric ordecorative shape consistent with the desired removal force and removalforce perception. The pressure applying members may be regularly orirregularly spaced, and may be oriented in various directions.

In some embodiments, a method as described herein is part of a methodfor making an absorbent article. For example, a method for making anabsorbent article may comprise providing a first substrate portion 11and a second substrate portion 12, each of the first 11 and secondsubstrate portions 12 having a melting temperature and an outer surface13, 14, the melting temperatures of the first 11 and second substrateportions 12 being substantially the same or substantially different. Thefirst substrate portion 11 may be placed adjacent at least the secondsubstrate portion 12 to form an overlap area 15. A fluid may besufficiently heated to enable at least a partial melting of the firstand second substrate portions 11, 12. A jet of the heated fluid may bedirected toward at least one of the outer surface 13 of the firstsubstrate portion 11 and the outer surface 14 of the second substrateportion 12. The fluid may be allowed to penetrate the first 11 andsecond substrate portions 12 such that at least a portion of each of thefirst 11 and second substrates 12 is melted in the overlap area 15. Thefirst substrate portion 11 and the second substrate portion 12 maycomprise a side panel, a front portion, a rear portion, or a combinationthereof. As discussed in more detail below, the absorbent article may bea pull-on diaper, as one example. The first and second substrateportions may be nonwoven materials. The first and second substrateportions may further comprise an elastic film. A method for making anabsorbent article may further comprise compressing overlap area 15. Thecompression of overlap area 15 may be performed after the partialmelting of substrate portions 11 and 12 in the overlap area 15. Forexample, the compression of overlap area 15 may occur within 5milliseconds, or 10 milliseconds, or 50 milliseconds of the partialmelting of substrate portions 11 and/or 12. In some embodiments, theoverlap area 15 may be compressed through multiple iterations. Oncecompressed, the substrate portions 11 and 12 may be cut into individualarticles, using, for example, a mechanical cutting device such as a flexblade or die knife. In some embodiments, it is to be appreciated thatthe substrate portions 11 and 12 are compressed and cut in a singlestep.

Substrate portions 11 and 12 may be non-woven substrates with a basisweight ranging from 10 to 500 grams per square meter, containing fibersranging from microfibers of less than one denier to conventional fibersranging from 1 to 7 denier. The non-woven substrates may also containelastic materials in the form of strands. Based in part on the thicknessof the substrates, the interval of time required to join the substrates11, 12 with this method may range from 5 to 2000 milliseconds. In someembodiments, 30 to 250 milliseconds may be used for heating and 5 to 250milliseconds may be used for compression/cooling. In some embodiments,the compression step may be very short, nearly instantaneous. The timeintervals used may vary with the nominal pressure and temperatureselections. A higher processing time may be tolerated by the materialswithout damage at lower pressure and/or temperature, whereas higherpressure and/or temperature may be used with shorter processing times.

At least one of the substrate portions 11 and 12 may comprise sufficientmeltable material that the substrate portion is susceptible to beingthermally joined to another substrate portion. Substrate portions 11, 12may be porous—air permeable, fluid permeable or vapor permeable—andsubstrate portion 11, substrate portion 12, or both substrate portions11 and 12 may comprise meltable components. Substrate portions 11, 12may be woven or non-woven, and may comprise fibers or polymeric binders,natural fibers such as cellulose—wood pulp, cotton, jute, hemp;synthetic fibers such as rayon, polyester, polyolefin, acrylic,polyamide, aramid, polytetrafluroethylene metal, polyimide,polypropylene, polyethylene; or binders such as bicomponent fibers,copolymer polyester, polyvinyl chloride, polyvinyl acetate/chloridecopolymer, copolymer polyamide, polyurethane-polyurea copolymer. Thesubstrate portions 11 and 12 may comprise blends of materials whereinsome of the constituent materials are not meltable. Substrate portions11, 12 may be of the same or different materials. Substrate portions 11,12 each have a melting temperature, and the melting temperature of thesubstrate portions 11, 12 may be different or substantially the same.The melting temperatures are substantially the same if they are within30° C. of each other. The melting temperatures of substrate portions 11,12 may be within 10° C. of each other, or within 5° C. of each other. Insome embodiments, the melting temperatures of substrate portions 11, 12are the same. As the difference between the melting temperatures ofsubstrate portions 11, 12 decreases, the ability to control the seam mayincrease.

The seaming process doses and disperses thermal energy in and around theoverlap area where a bond will be formed. In some instances, the lowerthe thermal energy delivered to form the bond, the less likely theprocess is to damage nearby materials or to impact layers adjacent theintended bond site. A jet of heated fluid, such as air for example, maybe dispersed through porous layers, or, where the melting temperature ofsubstrate portions 11, 12 is not the same, hot air may be used to form ahole through the outer layer, allowing penetration of the hot air to theinner substrate portion. Where substrate portions 11, 12 are each porousand the substrate portions 11, 12 have substantially the same meltingtemperature, a relatively low temperature, low pressure air stream maybe used, resulting in little damage to the fibers in and around the bondarea. In some instances, if one of the substrate portions 11, 12, oranother layer of material intervening between the hot air source andsubstrate portions 11, 12, is not porous or has a melting temperaturewhich is not substantially the same as the other layers, a relativelyhigh temperature, high pressure air stream may be needed.

Referring to FIG. 2, a simplified, diagrammatic drawing of a rotaryseaming apparatus 20 may be used for joining the substrate portions 11and 12 to form the seam 10. The rotary seaming apparatus 20 includes aforming cylinder 22 with pressure applying members 24 extending radiallyoutwardly from an outer circumferential surface 26 of the formingcylinder 22. It is to be appreciated that the forming cylinder 22 mayinclude one or more pressure applying members 24. The pressure applyingmembers 24 may include fluid outlets 28, each fluid outlet 28 includinga fluid orifice 30. The fluid outlet 28 is in fluid communication with afluid chamber 32 providing a pressurized fluid source for delivery ofheated, pressurized fluid, such as air for example, to the fluid outlet28. In some embodiments, a heating device 34 may be provided for heatingthe fluid within the fluid chamber 32. In some embodiments, a valve 36may control egress of fluid from the fluid chamber 32 and into the fluidoutlet 28.

As shown in FIG. 2, driving rolls 38 may be used to advance thesubstrate portions 11 and 12 in a machine direction MD onto the formingcylinder 22. The substrate portions 11 and 12 wrap around the outercircumferential surface of the forming cylinder 22 as it rotates. Oncereceived on the forming cylinder 22, heated, pressurized fluid isreleased from the fluid outlets to heat the substrate portions 11 and 12as the forming cylinder rotates. The at least partially melted substrateportions advance through a nip 40 between the forming cylinder 22 and ananvil cylinder 42. The anvil cylinder 42 may be positioned relative tothe forming cylinder 22 such that a pressure applying surface 44 of thepressure applying member 24 can compress the substrate portions 11 and12 together at the area of overlap 15 as the substrate portions 11 and12 advances through the nip 40. In some embodiments, the height of nip40 may be adjusted to control the pressure applied to the substrateportions 11 and 12 through the pressure applying members 24. Thepressure applied to the substrate portions 11 and 12 may, for example,be in the range of 1×10⁵ Newtons per square meter to 1×10⁸ Newtons persquare meter.

Although not shown in the figures, it is to be appreciated that theupstream ends or sources of the substrate portions 11, 12 and downstreamdestination of the seam 10 may have various different configurations.For example, the substrate portions 11 and 12 may originate in rollform, and there may be provided upstream unwinding, splicing and/orfolding means to enable forwarding continuous lengths of such substratesthrough joining means and/or converters to make substrate structures.Further, although the apparatus 20 is described herein as comprisingforming cylinder 22 and anvil cylinder 42, such description is notintended in any way to limit the method described to an apparatuscomprising cylinders.

Referring to FIG. 3, a simplified and partially sectioned view of theforming cylinder 22 with a representative pressure applying member 24 isshown. The pressure applying member 24 may include, for example, aconical or cylindrical shaped fluid outlet 28 through which the heatedfluid required to at least partially melt the meltable components of thesubstrate portions 11, 12 is directed. Although the following discussionrefers to a cylindrical shaped fluid outlet 28, it is to be appreciatedthat fluid outlets 28 having various other shapes may be used, such asfor example cones, boxes, and pyramids. A fluid jet nozzle may beconnected to a top face 50 of the fluid outlet 28. It is to beappreciated that the top face 50 and orifice 30 may be configured tohave various different sizes. For example, in some embodiments, thediameter of top face 50 of the cylindrical shaped fluid outlet 28 mayrange from 1 millimeter to 8 millimeters and the diameter of orifice 30of cylindrical shaped zone 34 may range from 0.1 millimeters to 6millimeters.

Heated fluid passing through the fluid outlet 28 is directed toward anarea of overlap 15 of substrate portions 11, 12 as the substrateportions 11, 12 advance in the machine direction MD through the nip 40between the forming cylinder 22 and an anvil cylinder 42. After theheated fluid partially melts meltable components of the substrateportions 11, 12, the pressure applying member 24 applies pressure andcompresses the partially melted components of the substrate portions 11,12 to join the substrate portions 11, 12 at seam 10. As previouslymentioned, the fluid may include ambient air or other gases. It is to beappreciated that the fluid may be heated to various temperatures andpressurized to various pressures. For example, in some embodiments, thefluid may be heated up to a temperature ranging from the lower meltingpoint of substrate portions 11, 12 minus 30° C. to the lower meltingpoint of substrate portions 11, 12 plus 100° C. In some exampleconfigurations, the fluid pressure may range from 0.1×10⁵ Newtons persquare meter to 1×10⁶ Newtons per square meter.

During operation, the fluid outlet 28 may move with the same speed orapproximately the same speed as the area of overlap 15 of the substrateportions 11, 12 for various time intervals to allow the heated fluid tobe directed toward at least one outer surface 13, 14. In someembodiments, the heated fluid may be directed toward at least one outersurface 13, 14 for a time interval ranging from 10 to 1000 millisecondsor greater. Shorter or greater time intervals may be used. It is to beappreciated that the pressure applying members 24 on the formingcylinder 22 may be disposed in a predetermined pattern, with eachpressure applying member 24 being configured and disposed to applypressure or compress the substrate portions 11, 12 together after thesubstrate portions 11, 12 have been at least partially melted by theheated fluid. In some embodiments, the forming cylinder 22 may havepressure applying members 24 which extend circumferentially about eachend of the forming cylinder 22.

Anvil cylinder 42 may be a smooth-surfaced, right circular cylinder ofsteel, which can be independently power-rotated by a speed controlleddirect current motor. The anvil cylinder 42 may also be rough-surfacedto form a textured bond. In some configurations, the anvil cylinder 42may move with the same speed as substrate portions 11, 12 at the area ofoverlap 15. During this time, the area of overlap 15 may be deformedusing the pressure applying member 24, whereby joining occurs andcooling follows. In some embodiments, the anvil cylinder 42 and thepressure applying member 24 may be coated to prevent the substrateportions 11, 12 from sticking to the anvil cylinder 42 and the pressureapplying member 24. It is to be appreciated that the anvil cylinder 42and the pressure applying member 24 may be coated with, for example, aplasma coating, polytetrafluroethylene, or silicone.

In some embodiments, cylinder actuators 43, 45 are provided to drive theforming cylinder 22 and anvil cylinder 42, such as shown in FIG. 2. Inaddition, there may be a predetermined but adjustable relationshipbetween the surface velocities of the forming cylinder 22 and the anvilcylinder 42. Such a relationship can be synchronous, or asynchronous,that is, with equal surface velocities or with a predetermined surfacevelocity differential with either the forming cylinder 22 or the anvilcylinder 42 being driven faster than the other. The driving rolls 38 maybe driven at surface velocities which maintain predetermined levels oftension or stretch so that neither slack substrate conditions norexcessively tensioned/stretched substrates precipitate undesirableconsequences. Nine drive rolls 38 are shown in FIG. 2, however, itshould be understood that more or fewer drive rolls may be used. In someembodiments, no drive rolls 38 may be needed, as substrate portions 11,12, and the joined substrates may be driven by elements incorporatedinto the forming cylinder 22 and/or the anvil cylinder 42 or by otherfunctional equipment upstream or downstream of apparatus 20.

With reference to FIG. 2 and FIG. 4, a seaming operation is shownwherein the substrate portions 11 and 12 advance in the machinedirection MD onto the outer circumferential surface 26 of the formingcylinder 22. As shown in FIG. 4, a jet 52 of heated fluid is directedtoward the substrate portions 11 and 12 at the overlap area 15. In someembodiments, the jet 52 of heated fluid may distribute in the machinedirection MD and/or cross direction CD as the heated fluid is directedtoward the substrate portions 11 and 12 forming substantially a coneshape such that the width W at the base of the jet 52 is greater thanthe diameter D of the fluid orifice 30. While the jet 52 may be a coneshape, other spray patterns are possible, such as for example,cylindrical, fan-shaped, and which may depend, at least in part, on theshape of the fluid orifice 30 and fluid outlet 28, the pressure of thefluid and type of fluid being used.

With continued reference to FIG. 4, in some embodiments, the substrateportions 11 and 12 may be maintained a preselected distance Y from thefluid orifice 30, for example, using the pressure applying member 24.The pressure applying member 24 may be positioned to limit verticalmovement of the substrate portions 11 and 12 toward and/or away from thefluid orifice 30 as the substrate portions 11 and 12 are heated duringthe seaming operation. In some embodiments, the distance Y between theouter surface 13 of the substrate portion 11 facing the fluid orifice 30may be between about 0 mm and about 20 mm, such as between about 0 mmand about 5 mm, such as between about 0.5 mm and about 3 mm. Thedistance Y between the outer surface 13 of the substrate portion 11facing the fluid orifice 30 may be maintained within 3 mm of thepreselected distance Y. Control of the distance Y may also result in arelatively more predictable fluid spray and melt pattern during theheating process.

In some embodiments, the forming cylinder 22 may be rotating at aconstant speed, decreasing speed, increasing speed, or may be stationarywhile the jet 52 of heated fluid at least partially melts the substrateportions 11 and 12. Once the substrate portions 11 and 12 are at leastpartially melted, the pressure applying surface 44 of the pressureapplying member 24 contacts the substrate portions 11 and 12 at theoverlapping, at least partially melted area 15. The pressure applyingmember 24 compresses the substrate portions 11 and 12 together betweenthe pressure applying surface 44 and the anvil cylinder 42. While asingle fluid outlet 28 and jet 52 are illustrated in FIG. 4, multiplefluid outlets may be provided, for example, such that multiple jets ofheated fluid may be used to at least partially melt the substrateportions 11 and 12.

In some embodiments, a position control member may be used to maintainthe absorbent articles within a constant distance from the outercircumferential surface of the forming cylinder as the fluid is heatingthe overlap area. The position control device may be positioned to limitvertical movement of the substrate portions and toward and/or away fromthe fluid orifice as during the seaming operation. In some embodiments,the position control member may be a belt. The position control membermay be located adjacent the forming cylinder and may take the shape ofat least a portion of the forming cylinder. The position control membermay hold the substrates in the range of 0 millimeters to about 10millimeters from the forming cylinder, or between about 0.5 millimetersto about 5 millimeters from the forming cylinder.

FIG. 5 shows an embodiment of a translational seaming apparatus 60 thatmay be used for joining the substrate portions 11 and 12 to form theseam 10. The translational seaming apparatus 60 includes a forming block62 (shown diagrammatically in section) with a pressure applying member64 extending outwardly from a face 66 of the forming block 62. While asingle pressure applying member 64 is illustrated, there may be morethan one pressure applying member. Adjacent and spaced laterally fromthe pressure applying member 64 is a fluid outlet 68 including a fluidorifice 70. The fluid outlet 68 is in fluid communication with a fluidchamber 71 providing a pressurized fluid source for delivery of heated,pressurized fluid to the fluid outlet 68. A heating device 72 may beprovided for heating the fluid within the fluid chamber 70. In someembodiments, a valve may control egress of fluid from the fluid chamber70 and into the fluid outlet 68.

Similar to the apparatus 20 described above, driving rolls 74 may beused for supplying the substrate portions 11 and 12 to an opening 76between the forming block 62 and an anvil block 77. The anvil block 76is positioned to allow a pressure applying surface 78 of the pressureapplying member 64 to compress the substrate portions 11 and 12 togetherat the area of overlap 15. As discussed above, a position control membermay be used to maintain the absorbent articles within a constantdistance from the forming block as the fluid is heating the overlaparea. The position control member may hold the substrates in the rangeof 0 millimeters to about 20 millimeters from the forming block, orbetween about 0.5 millimeters to about 5 millimeters from the formingblock.

A seaming operation is shown in FIGS. 6A and 6B, wherein the substrateportions 11 and 12 advance in the machine direction MD through theopening 76 between the forming block 62 and the anvil block (not shownfor clarity). A jet 84 of heated fluid (e.g., air) is directed towardthe substrate portions 11 and 12 at the overlap area 15. As can be seenby FIG. 6A, the jet 84 of heated fluid may distribute in the machinedirection MD and cross direction CD as it approaches the substrateportions 11 and 12 forming substantially a cone shape such that thewidth W at the base of the jet 84 is greater than the diameter D of thefluid orifice 70. While the jet 84 may be a cone shape, other spraypatterns are possible, such as cylindrical, fan-shaped, etc., which maydepend, at least in part, on the shape of the fluid orifice 70 and fluidoutlet 68, the pressure of the fluid and type of fluid being used.

The substrate portions 11 and 12 may be maintained a preselecteddistance Y from the fluid orifice 70, for example, using a positioncontrol device. In some embodiments, the distance Y between the outersurface 13 of the substrate portion 11 facing the fluid orifice 30 maybe between about 0 mm and about 20 mm; between about 0 mm and about 5mm; or between about 0.5 and about 3 mm. Control of the distance Y mayalso result in a relatively more predictable fluid spray and meltpattern during the heating process.

The pressure applying member 64 and the fluid orifice 70 may also beseparated from each other. For example, as shown FIGS. 6A and 6B, thefluid orifice 70 is offset laterally from the pressure applying member64. The fluid orifice 70 may be offset from the pressure applying membera distance such that the pressure applying member 64 does not intersectthe jet 84 at any portion along the distance Y. Additionally, thepressure applying surface 78 of the pressure applying member 64 isspaced away from the substrate portions 11 and 12 during the heatingoperation. Thus, the pressure applying member 64 does not interfere withthe heating of the substrate portions 11 and 12 by the jet 84 of heatedfluid.

The forming block 62 may be moving at a constant speed, decreasingspeed, increasing speed, or may be stationary while the jet 84 of heatedfluid at least partially melts the substrate portions 11 and 12. Oncethe substrate portions 11 and 12 are at least partially melted, theforming block 62 may move toward the substrate portions 11 and 12 (bothin the machine direction MD and vertically as shown by arrows 65 and 67)and the pressure applying surface 78 of the pressure applying member 64contacts the substrate portions 11 and 12 at the overlapping, at leastpartially melted area 15. The pressure applying member 64 compresses thesubstrate portions 11 and 12 together between the pressure applyingsurface 78 and the anvil block 76.

FIG. 7 illustrates another translational seaming apparatus 90 that maybe used for joining the substrate portions 11 and 12 to form the seam10. A forming block 92 includes many of the same or similar features asforming block 62 shown in FIG. 5, including a pressure applying member94 extending outwardly from a face 96 of the forming block 92 and afluid outlet 98 including a fluid orifice 100 that is spaced from thepressure applying member 94. The fluid outlet 98 is in fluidcommunication with a fluid chamber 103 providing a pressurized fluidsource for delivery of heated, pressurized fluid to the fluid outlet 98.

In the embodiment of FIG. 7, the fluid outlet 98 is arranged at an angleto vertical, such as for example between about 0 and about 75 degrees;between about 30 and 60 degrees; or about 45 degrees. As such, the fluidoutlet 98 directs a jet 104 of heated fluid to a location at leastpartially beneath the pressure applying member 94 with a pressureapplying surface 106 of the pressure applying member 94 spaced away fromthe substrate portions 11 and 12. The pressure applying member 94 andthe fluid orifice 100 are separated from each other. In the illustratedexample, the fluid orifice 100 is offset laterally from the pressureapplying member 94 a distance such that the pressure applying member 100does not intersect the jet 104 at any portion along the height of thejet 104. Additionally, the pressure applying surface 106 of the pressureapplying member 94 is spaced away from the substrate portions 11 and 12during the heating operation. Thus, the pressure applying member 94 doesnot interfere with the heating of the substrate portions 11 and 12 bythe jet 104 of heated fluid.

The forming block 92 may be stationary while the jet 104 of heated fluidat least partially melts the substrate portions 11 and 12. Once thesubstrate portions 11 and 12 are at least partially melted, the formingblock 92 may move in a vertical direction in the direction of arrows 109toward the substrate portions 11 and 12 and the pressure applyingsurface 106 of the pressure applying member 94 contacts the substrateportions 11 and 12 at the overlapping, at least partially melted area15. The pressure applying member 94 compresses the substrate portions 11and 12 together between the pressure applying surface 106 and the anvilblock.

In some embodiments, it is to be appreciated that the translationalseaming apparatuses of FIGS. 6A, 6B, and 7 may be integral with a rotarydrum apparatus. For example, the drum may oscillate such that thepressure applying member shifts relative to the substrate portions. Aposition control device may be used to maintain the absorbent articleswithin a constant distance from the rotary drum apparatus as the fluidis heating the overlap area. The position control device may bepositioned to limit vertical movement of the substrate portions andtoward and/or away from the fluid orifice as during the seamingoperation. In some embodiments, the position control member may be abelt.

FIG. 8 shows a simplified, diagrammatic drawing of another embodiment ofa rotary seaming apparatus 110 that may be used for joining thesubstrate portions 11 and 12 to form the seam 10. The rotary seamingapparatus 110 includes a heating cylinder 112 (shown diagrammatically insection) with a plurality of fluid outlets 114 disposed about aperiphery 116 of the heating cylinder 112. The fluid outlets 114 areeach in communication with a fluid chamber 118 providing a pressurizedfluid source for delivery of heated, pressurized fluid to the fluidoutlets 114. A heating device 120 may be provided for heating the fluidwithin the fluid chamber 118. In some embodiments, valves may controlegress of fluid from the fluid chamber 118 and into the fluid outlets114.

With continued reference to FIG. 8, the heating cylinder 112 advancesthe substrate portions 11 and 12 to a nip 122 formed between an anvilcylinder 124 and a pressure applying cylinder 126. The pressure applyingcylinder 126 may include a plurality of pressure applying members 128disposed about a periphery 130 of the pressure applying cylinder 126. Inother embodiments, the anvil cylinder 124 may be replaced by thepressure applying cylinder 126.

In operation, the substrate portions 11 and 12 are advanced in themachine direction MD to the periphery 116 of the heating cylinder 112and travel about the heating cylinder 112 as the heating cylinder 112rotates. Heated fluid is delivered to the substrate portions 11 and 12through the plurality of fluid outlets 114 thereby at least partiallymelting overlapped areas of the substrate portions 11 and 12. Becausethe substrate portions 11 and 12 travel with the rotating heatingcylinder 112, heating of the substrate portions 11 and 12 may befacilitated by matching the travel speed of the substrate portions 11and 12 with the surface speed of the heating cylinder 112. In someembodiments, the substrate portions 11 and 12 may also travel apredetermined contact angle, such as for example 45 degrees or more,around the periphery 116 of the heating cylinder 112. In someembodiments, the contact angle is selected to allow heating ofoverlapped areas 15 of the substrate portions 11 and 12 for betweenabout 5 and about 2000 milliseconds, such as between about 10 and about500 milliseconds, such as between about 20 and about 200 milliseconds.

Once heated, the substrate portions 11 and 12 advance to the nip 122formed between the rotating anvil cylinder 124 and the rotating pressureapplying cylinder 126. As the cylinders 124 and 126 rotate, thesubstrate portions 11 and 12 are pulled into the nip 122 and thepressure applying members 128 then compress the at least partiallymelted, overlapping areas 15 thereby forming the seam 10 and joining thesubstrate portions 11 and 12 together.

FIG. 9 shows an embodiment of a traversing seaming apparatus 140 thatmay be used for joining the substrate portions 11 and 12 to form theseam 10. The traversing seaming apparatus 140 includes a forming block142 with a plurality of pressure applying members 144 extendingoutwardly from a face 146 of the forming block 142. Any suitable numberof pressure applying members 144 may be utilized. An anvil block 150 islocated adjacent the forming block 142 defining a opening 152therebetween. In some embodiments, the anvil block 150 may be connectedto the forming block 142 by any suitable connection that allows theanvil block 150 and/or the forming block 142 to move toward and awayfrom the other. For example, an actuator, such as a pneumatic or ahydraulic actuator, may be provided that moves one or both of the anvilblock 150 and the forming block 142 toward and away from one another. Insome embodiments, the forming block 142 and the anvil block 150 may besupported separately and one or both may include their own actuator formoving the forming and anvil blocks 142 and 150.

A heating block 156 (shown diagrammatically in section) that includes aplurality of fluid outlets 158 shown in FIG. 9 is adjacent and spacedlaterally from the forming and anvil blocks 142 and 150. The fluidoutlets 158 are in fluid communication with a fluid chamber 160providing a pressurized fluid source for delivery of heated, pressurizedfluid (e.g., air) to the fluid outlets 158. A heating device 162 may beprovided for heating the fluid within the fluid chamber 160. In someembodiments, a valve may control egress of fluid from the fluid chamber160 and into the fluid outlets 158.

Similar to the apparatus described above, driving rolls (not shown) maybe used to advance the substrate portions 11 and 12 in the machinedirection MD to the opening 152 between the forming block 142 and theanvil block 150. The anvil block 150 is positioned to allow pressureapplying surfaces of the pressure applying members 144 to compress thesubstrate portions 11 and 12 together at the area of overlap 15.

In operation, the substrate portions 11 and 12 are moved to a positionadjacent the heating block 156. Jets of heated fluid are directed towardthe substrate portions 11 and 12 at the overlap area 15. As discussedabove, the substrate portions 11 and 12 may be maintained a preselecteddistance from the fluid outlets 158, for example, using a positioncontrol device. During the heating operation, the substrate portions 11and 12 may be stationary for a preselected amount of time to allow forthe at least partial melting of the substrate portions 11 and 12 at theoverlap areas 15. Once at least partially melted, the substrate portions11 and 12 may advance to the opening 152 between the forming block 142and an anvil block 150. One or both of the forming block 142 and theanvil block 150 may be moved toward the other thereby compressing thesubstrate portions 11 and 12 together at the at least partially melted,overlap areas 15.

FIG. 10 shows another embodiment of a traversing seaming apparatus 170for joining the substrate portions 11 and 12 to form the seam 10. Thetraversing seaming apparatus 170 includes a heating and forming block184 (shown diagrammatically in section) and an anvil block 180 formingan opening 182 between the anvil block 180 and the heating and formingblock 184. The heating and forming block 184 may include both pressureapplying members 186 that extend outwardly from a face 188 of theheating and forming block 184 and fluid outlets 190 that are each incommunication with a fluid chamber 192 providing a pressurized fluidsource for delivery of heated, pressurized fluid to the fluid outlets190. A heating device 194 may be provided for heating the fluid withinthe fluid chamber 192. In some embodiments, valves may control egress offluid from the fluid chamber 192 and into the fluid outlets 190.

Referring back to FIG. 10, in operation, the substrate portions 11 and12 are moved to the opening 182 between the heating and forming block184 and the anvil block 180. Jets of heated fluid are directed towardthe substrate portions 11 and 12 at the overlap area 15. As above, thesubstrate portions 11 and 12 may be maintained a preselected distancefrom the fluid outlets 190, for example, using a position controldevice. During the heating operation, the substrate portions 11 and 12may be stationary for a preselected amount of time to allow for the atleast partial melting of the substrate portions 11 and 12 at the overlapareas 15. Once at least partially melted, one or both of the heating andforming block 184 and the anvil block 180 may be moved toward the otherthereby compressing the substrate portions 11 and 12 together at the atleast partially melted, overlap areas 15.

Although some embodiments have been shown with a fluid outlet locatedaway from and/or apart from the pressure applying member, it is to beappreciated that the fluid outlet may be configured so as to be combinedwith the pressure applying member. For example, FIG. 11 shows anembodiment with a combination fluid outlet 190 and pressure applyingmember 186. The pressure applying member 186 includes an outer wall 196extending outwardly from the face 188 of the heating and forming block184, an inner wall 198 extending downwardly toward a fluid orifice 200of the fluid outlet 190 and a pressure applying surface 202 extendingbetween the outer wall 196 and the inner wall 198. As can be seen, thefluid orifice 200 is spaced vertically or recessed behind the pressureapplying surface 202. Such an arrangement can help inhibit clogging ofthe fluid orifice 200, for example, by the substrate material when thepressure applying surface 202 contacts the substrate portions 11 and 12.While the pressure applying member 186 is illustrated as tubular orcylindrical extending around the entire periphery of the fluid outlet190, other configurations are possible.

FIG. 4B shows another example of a combination fluid outlet 204 andpressure applying member 206. The pressure applying member 206 includesan outer wall 208 extending outwardly from the face 188 of the heatingand forming block 184, an inner wall 210 extending downwardly toward afluid orifice 203 of the fluid outlet 204 and a pressure applyingsurface 212 extending between the outer wall 208 and the inner wall 210.As above, the fluid orifice 203 is spaced vertically or recessed behindthe pressure applying surface 212. Unlike the pressure applying member186, however, the pressure applying member 206 is U or horseshoe shapedand extends about only part of fluid outlet 204. Any other suitableshapes may be used, such as irregular shapes, squares, rectangles, etc.

FIG. 11 shows another embodiment of a traversing seaming apparatus 220for joining the substrate portions 11 and 12 to form the seam 10. Theapparatus 220 includes an anvil cylinder 222 and at least one formingblock assembly 224 that rotates with the anvil cylinder 222. Theapparatus 220 shown in FIG. 11 includes four forming block assembliesspaced ninety degrees about the periphery of the anvil cylinder 222.Each forming block assembly 224 includes a cam follower 226 that engagea cam surface 228 of a cam member 230 to control movement of the formingblock assemblies 224 toward and away from the anvil cylinder 222. Asshown in FIG. 11A, the forming block assemblies 224 include a pressureapplying member 232 extending outwardly from a face 234 of the blockassemblies 224 toward the anvil cylinder 222. The forming blockassemblies also include a fluid outlet 236 spaced laterally from thepressure applying member 232 in communication with a fluid chamberproviding a pressurized fluid source for delivery of heated, pressurizedfluid to the fluid outlets 236.

With continued reference to FIG. 11A, the block assembly 224 rotateswith the anvil cylinder 222 at a location adjacent the anvil cylinder222 and spaced radially away a distance X₁ from the periphery of theanvil cylinder 222. The substrate portions 11 and 12 are advanced in themachine direction MD to the periphery of the anvil cylinder 222 as theanvil cylinder 222 rotates. As shown in FIG. 11B, the block assembly 224moves laterally a distance Y₁ to a location above the periphery of theanvil cylinder 222 and the substrate portions 11 and 12. The camfollower 226 engages the cam surface 228 of the cam member 230 whichcontrollably moves the block assembly 224 toward the substrate portions11 and 12 a distance X₂ from the periphery of the anvil cylinder 222.

Jets of heated fluid are directed toward the substrate portions 11 and12 at the overlap area 15. As previously discussed, the substrateportions 11 and 12 may be maintained a preselected distance from thefluid outlets 236 using the cam surface 228. During the heatingoperation, the substrate portions 11 and 12 may move together, or atsubstantially the same rate, to allow for the at least partial meltingof the substrate portions 11 and 12 at the overlap areas 15. Once atleast partially melted, the block assembly 224 may advance to a distanceY₂ as shown in FIG. 11C. The forming block assembly 224 may also movetoward the periphery of the anvil cylinder 222 to a distance X₃ therebycompressing the substrate portions 11 and 12 together at the at leastpartially melted, overlap areas 15.

The following addresses some distinctions with respect to the meltingtemperatures of the layers in the seam. If one or more layers had asubstantially different melting temperature than another layer orlayers, the air temperature, the length of time the materials areexposed to the heated air, or both, may be adjusted to accommodate thehighest melting temperature in the seam. It has been found that in someinstances, selecting seam materials for like melting temperatures, aseam between substrates of like melting temperature may provide moreconsistent bonds.

Using substrate portions of like melting temperature may also provideprocessing benefits. When the process parameters are adjusted for arelatively high melting temperature, substrates in the seam having alower melting temperature may be damaged during processing. To helplimit such damage, a relatively small orifice may be used to confine theflow of hot air to a limited area. Using more moderate temperatures anddwell times, relative to the melting temperatures of the substrates inthe seam, it may be possible to use a larger orifice. A larger orificemay be less prone to tool contamination, and therefore require lessfrequent or less intense cleaning and maintenance. Further, it may bepossible to reduce the dwell times that the seam materials are exposedto hot air, resulting in faster processing.

As previously mentioned, the processes and apparatuses discussed hereinmay be used to bond various types of substrate configurations, some ofwhich may be used in the manufacture of different types of absorbentarticles. To help provide additional context to the subsequentdiscussion of the process embodiments, the following provides a generaldescription of absorbent articles in the form of diapers that includecomponents that may be bonded in accordance with the methods andapparatuses disclosed herein.

FIGS. 12 and 13 show an example of a diaper pant 300 that may beassembled and folded in accordance with the apparatuses and methodsdisclosed herein. In particular, FIG. 12 shows a perspective view of adiaper pant 300 in a pre-fastened configuration, and FIG. 13 shows aplan view of the diaper pant 300 with the portion of the diaper thatfaces away from a wearer oriented toward the viewer. The diaper pant 300shown in FIGS. 12 and 13 includes a chassis 302 and first and secondsubstrate portions 11 and 12, forming a ring-like elastic belt 304. Asdiscussed below in more detail, the first substrate portion 11 in theform of a first elastic belt 306 and the second substrate portion 12 inthe form of a second elastic belt 308 are connected together to form thering-like elastic belt 304.

With continued reference to FIG. 13, the chassis 302 includes a firstwaist region 316, a second waist region 318, and a crotch region 320disposed intermediate the first and second waist regions. The firstwaist region 316 may be configured as a front waist region, and thesecond waist region 318 may be configured as back waist region. In someembodiments, the length of each of the front waist region, back waistregion, and crotch region may be ⅓ of the length of the absorbentarticle 300. The diaper 300 may also include a laterally extending frontwaist edge 321 in the front waist region 316 and a longitudinallyopposing and laterally extending back waist edge 322 in the back waistregion 318. To provide a frame of reference for the present discussion,the diaper 300 and chassis 302 of FIG. 13 are shown with a longitudinalaxis 324 and a lateral axis 326. In some embodiments, the longitudinalaxis 324 may extend through the front waist edge 321 and through theback waist edge 322. And the lateral axis 326 may extend through a firstlongitudinal or right side edge 328 and through a midpoint of a secondlongitudinal or left side edge 330 of the chassis 302.

As shown in FIGS. 12 and 13, the diaper pant 300 may include an inner,body facing surface 332, and an outer, garment facing surface 334. Thechassis 302 may include a backsheet 336 and a topsheet 338. The chassis302 may also include an absorbent assembly 340 including an absorbentcore 342 may be disposed between a portion of the topsheet 338 and thebacksheet 336. As discussed in more detail below, the diaper 300 mayalso include other features, such as leg elastics and/or leg cuffs toenhance the fit around the legs of the wearer.

As shown in FIG. 13, the periphery of the chassis 302 may be defined bythe first longitudinal side edge 328, a second longitudinal side edge330; a first laterally extending end edge 344 disposed in the firstwaist region 316; and a second laterally extending end edge 346 disposedin the second waist region 318. Both side edges 328 and 330 extendlongitudinally between the first end edge 344 and the second end edge346. As shown in FIG. 13, the laterally extending end edges 344 and 346are located longitudinally inward from the laterally extending frontwaist edge 321 in the front waist region 316 and the laterally extendingback waist edge 322 in the back waist region 318. When the diaper pant300 is worn on the lower torso of a wearer, the front waist edge 321 andthe back waist edge 322 of the chassis 302 may encircle a portion of thewaist of the wearer. At the same time, the chassis side edges 328 and130 may encircle at least a portion of the legs of the wearer. And thecrotch region 320 may be generally positioned between the legs of thewearer with the absorbent core 342 extending from the front waist region316 through the crotch region 320 to the back waist region 318.

It is to also be appreciated that a portion or the whole of the diaper300 may also be made laterally extensible. The additional extensibilitymay help allow the diaper 300 to conform to the body of a wearer duringmovement by the wearer. The additional extensibility may also help, forexample, allow the user of the diaper 300 including a chassis 302 havinga particular size before extension to extend the front waist region 316,the back waist region 318, or both waist regions of the diaper 300and/or chassis 302 to provide additional body coverage for wearers ofdiffering size, i.e., to tailor the diaper to an individual wearer. Suchextension of the waist region or regions may give the absorbent articlea generally hourglass shape, so long as the crotch region is extended toa relatively lesser degree than the waist region or regions, and mayimpart a tailored appearance to the article when it is worn.

The first and second elastic belts 306, 308 may also each include beltelastic material interposed between the outer layer 362 and the innerlayer 364. The belt elastic material may include one or more elasticelements such as strands, ribbons, or panels extending along the lengthsof the elastic belts. As shown in FIGS. 13, 15A, and 15B, the beltelastic material may include a plurality of elastic strands 368 whichmay be referred to herein as outer, waist elastics 370 and inner, waistelastics 372. As shown in FIG. 13, the elastic strands 368 continuouslyextend laterally between the first and second opposing end regions 306a, 306 b of the first elastic belt 306 and between the first and secondopposing end regions 308 a, 308 b of the second elastic belt 308. Insome embodiments, some elastic strands 368 may be configured withdiscontinuities in areas, such as for example, where the first andsecond elastic belts 306, 308 overlap the absorbent assembly 340. Insome embodiments, the elastic strands 368 may be disposed at a constantinterval in the longitudinal direction. In other embodiments, theelastic strands 368 may be disposed at different intervals in thelongitudinal direction. The belt elastic material in a stretchedcondition may be interposed and joined between the uncontracted outerlayer and the uncontracted inner layer. When the belt elastic materialis relaxed, the belt elastic material returns to an unstretchedcondition and contracts the outer layer and the inner layer. The beltelastic material may provide a desired variation of contraction force inthe area of the ring-like elastic belt.

It is to be appreciated that the chassis 302 and elastic belts 306, 308may be configured in different ways other than as depicted in FIG. 13.For example, FIG. 14 shows a plan view of a diaper pant 300 having thesame components as described above with reference to FIG. 13, except thefirst laterally extending end edge 344 of the chassis 302 is alignedalong and coincides with the outer lateral edge 307 a of the firstelastic belt 306, and the second laterally extending end edge 346 isaligned along and coincides with the outer lateral edge 309 a of thesecond belt 308.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for forming a seam, the methodcomprising the steps of: providing an anvil block; providing a formingblock adjacent the anvil block, the forming block comprising a face, apressure applying member extending outwardly from the face toward theanvil block, and a fluid orifice in the face spaced laterally from thepressure applying member; advancing a first substrate in a machinedirection between the forming block and the anvil block with aseparation distance between the fluid orifice and the first substrate;advancing a second substrate in the machine direction wherein the firstsubstrate is between the second substrate and the forming block;controlling the separation distance between the first substrate and thefluid orifice; heating a fluid to a temperature sufficient to at leastpartially melt the substrates; directing a jet of the heated fluidthrough the fluid orifice and onto an overlap area of the first andsecond substrates; partially melting the overlap area; and compressingthe overlap area between the pressure applying member and the anvilblock.
 2. The method of claim 1, wherein the separation distance betweenthe fluid orifice and the first substrate is no greater than about 5 mm.3. The method of claim 1, further comprising moving the forming block inthe machine direction toward the overlap prior to the step ofcompressing the overlap area.
 4. The method of claim 1, wherein the jetof heated fluid is at a temperature ranging from a lower melting pointof the first and second substrates minus 30° C. to the lower meltingpoint of the first and second substrates plus 100° C.
 5. The method ofclaim 1, wherein the jet of heated fluid is directed at the first andsecond substrates at a pressure in the range of about 0.1×10⁵ Newtonsper square meter to about 1×10⁶ Newtons per square meter.
 6. The methodof claim 1, wherein the fluid is ambient air.
 7. The method of claim 1,further comprising heating the substrate portions using the jet of theheating fluid for between about 5 milliseconds and about 2000milliseconds.
 8. The method of claim 1, wherein the compressing stepcuts the overlap area.
 9. The method of claim 1, further comprisingadvancing a third substrate in the machine direction, wherein the thirdsubstrate is between the second substrate and the first substrate. 10.The method of claim 1, further comprising the step of moving the formingblock in at a vertical direction, wherein the vertical direction isperpendicular to the machine direction.
 11. A method for forming a seam,the method comprising the steps of: providing an anvil block; providinga forming block adjacent the anvil block, the forming block comprising aface, a pressure applying member extending outwardly from the facetoward the anvil block, and a fluid outlet extending through a portionof the forming block and spaced laterally from the pressure applyingmember; advancing a first substrate in a machine direction between theforming block and the anvil block with a separation distance between thefluid orifice and the first substrate; advancing a second substrate inthe machine direction wherein the first substrate is between the secondsubstrate and the forming block; controlling the separation distancebetween the first substrate and the fluid orifice; heating a fluid to atemperature sufficient to at least partially melt the substrates;directing a jet of the heated fluid through the fluid orifice and ontoan overlap area of the first and second substrates; partially meltingthe overlap area; and compressing the overlap area between the pressureapplying member and the anvil block.
 12. The method of claim 11, whereinthe fluid outlet extends in a direction perpendicular to the machinedirection.
 13. The method of claim 11, wherein the fluid outlet extendsin a direction at an angle to a vertical direction, wherein the verticaldirection is perpendicular to the machine direction.
 14. The method ofclaim 13, wherein the angle is from about 5 degrees to about 75 degreesto the vertical direction.
 15. The method of claim 13, wherein the angleis from about 30 degrees to about 60 degrees to the vertical direction.16. A method for forming a seam, the method comprising the steps of:providing an anvil block; providing a forming block adjacent the anvilblock, the forming block comprising a face, a pressure applying memberextending outwardly from the face toward the anvil block, and a fluidoutlet combined with the pressure applying member; advancing a firstsubstrate in a machine direction between the forming block and the anvilblock with a separation distance between the fluid orifice and the firstsubstrate; advancing a second substrate in the machine direction whereinthe first substrate is between the second substrate and the formingblock; controlling the separation distance between the first substrateand the fluid orifice; heating a fluid to a temperature sufficient to atleast partially melt the substrates; directing a jet of the heated fluidthrough the fluid orifice and onto an overlap area of the first andsecond substrates; partially melting the overlap area; and compressingthe overlap area between the pressure applying member and the anvilblock.
 17. The method of claim 16, further comprising moving the formingblock in the machine direction toward the overlap prior to the step ofcompressing the overlap area.
 18. The method of claim 16, wherein thejet of heated fluid is at a temperature ranging from a lower meltingpoint of the first and second substrates minus 30° C. to the lowermelting point of the first and second substrates plus 100° C.
 19. Themethod of claim 16, wherein the jet of heated fluid is directed at thefirst and second substrates at a pressure in the range of about 0.1×10⁵Newtons per square meter to about 1×10⁶ Newtons per square meter. 20.The method of claim 16, wherein the fluid is ambient air.